Process of high purity albumin production

ABSTRACT

A process is provided for the preparation of albumin from a yeast culture medium which has extremely low levels of or is essentially free of colorants, metal ions, human proteins, host proteins, fragments of albumin, polymers or aggregates of albumin and viruses, and which is essentially non-glycated, relatively high in free thiol and with an intact C-terminus. The process comprises separating the yeast from the culture medium to yield an albumin solution; subjecting the albumin solution to positive mode cation exchange, affinity, and positive mode anion exchange chromatography; and concentrating and formulating the albumin with sodium octanoate and sodium chloride.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.10/873,504, filed Jun. 22, 2004, now U.S. Pat. No. 7,223,561, which is acontinuation of U.S. application Ser. No. 10/301,357, filed Nov. 21,2002, now abandoned, which is a continuation of U.S. application Ser.No. 08/952,558, filed Feb. 24, 1999, now U.S. Pat. No. 6,638,740, whichis a continuation-in-part of U.S. application Ser. No. 08/378,859, fliedMay 25, 1995, now U.S. Pat. No. 5,728,553, the contents of which arehereby incorporated herein by reference.

The present invention relates to purifying the protein human serumalbumin (HSA) extracted from serum or recombinant human albumin (rHA)produced by transforming a microorganism with a nucleotide codingsequence encoding the amino acid sequence of human serum albumin. Inthis specification, the term albumin refers generically to HSA and/orrHA.

Albumin is used to treat patients with severe burns, shock or bloodloss. It is also used to supplement media used for growing highereukaryotic cells and as an excipient in the formulation of therapeuticproteins. At present, the demand for the product is satisfied by albuminextracted from human blood. Examples of extraction and separationtechniques include those disclosed in: JP 03/258 728 on the use of acation exchanger; EP 428 758 on the use of anion exchange followed bycation exchange; and EP 452 753 on the use of heating, adding salt anddiafiltering.

The production of rHA in microorganisms has been disclosed in EP 330 451and EP 361 991. Purification techniques for rHA have been disclosed in:WO 92/04367, removal of matrix-derived dye; EP 464 590, removal ofyeast-derived colorants; and EP 319 067, alkaline precipitation andsubsequent application of the rHA to a lipophilic phase having specificaffinity for albumin.

The present invention provides highly purified albumin.

One aspect of the present invention provides a process for purifyingalbumin, the process comprising the steps of applying a relativelyimpure albumin solution to a chromatographic material for which thealbumin has no specific affinity such that albumin binds to thematerial, and eluting the bound albumin from the material by applying asolution of a compound having a specific affinity for albumin.Preferably, the chromatographic material is a cation exchanger, such asSP-Sepharose FF, SP-Spherosil etc, as listed below in Example 2.

The compound with specific affinity for albumin may be octanoate (egsodium octanoate), other long chain (C₆ to C₂₂) fatty acids, salicylate,octylsuccinate, N-acetyltryptophan or a mixture of two or more of these.

A second aspect of the invention provides a process for purifyingalbumin, the process comprising the steps of subjecting an albuminsolution to cation exchange chromatography in which the albumin is boundto a cation exchange material and then anion exchange chromatography inwhich the albumin is bound to an anion exchange material.

The albumin which is eluted from the cation exchange material may besubsequently treated by one or more of affinity chromatography,ultrafiltration and gel permeation before being subjected to the saidanion exchange chromatography. Hence, in a preferred embodiment, theprocess comprises the steps of:

-   -   (a) passing an albumin solution through a cation exchange matrix        under conditions such that the albumin will bind to the matrix;    -   (b) eluting from said matrix an albumin-containing cation        exchange eluate;    -   (c) passing said eluate through an affinity matrix comprising an        albumin-binding compound;    -   (d) eluting from said matrix an albumin-containing affinity        matrix eluate;    -   (e) passing said eluate, optionally after ultrafiltration,        through a gel permeation matrix to obtain a fraction enriched in        albumin;    -   (f) passing the said albumin-enriched fraction through an anion        exchange matrix under conditions such that albumin will bind to        the matrix; and    -   (g) eluting from said anion exchange matrix a purified        albumin-containing product.

Alternatively, the albumin which is eluted from the cation exchangematerial may be applied to the said anion exchange material without anyintervening treatment (other than dilution). Hence, a second preferredembodiment provides a process for purifying albumin, comprising thesteps of:

-   -   (a) passing an albumin solution through a cation exchange matrix        under conditions such that the albumin will bind to the matrix;    -   (b) eluting from the matrix an albumin-containing cation        exchange eluate;    -   (c) passing the cation exchange eluate through an anion exchange        matrix under conditions such that the albumin will bind to the        matrix;    -   (d) eluting from the anion exchange matrix an albumin-containing        anion exchange eluate;    -   (e) passing the anion exchange eluate through an affinity matrix        comprising an albumin-binding compound;    -   (f) eluting from the affinity matrix an albumin-containing        affinity matrix eluate;    -   (g) passing the affinity matrix eluate through a gel permeation        matrix to obtain a fraction enriched in albumin.

Preferably, prior to the cation exchange step, the albumin solution isconditioned by adding octanoate and/or other albumin stabiliser (egsodium acetyltryptophanate) thereto to a final concentration of fromabout 1-10 mM and adjusting the pH to about 4.0-5.0.

Advantageously, the albumin retained in the cation exchange step iswashed with a high salt solution (eg 0.5-2.0 M NaCl buffered at pH 4.0with 10-100 mM, preferably 20-40 mM, for example 27 mM sodium acetate)before being eluted.

Preferably, in processes in which the cation exchange eluate is passeddirectly to the anion exchanger, the albumin is eluted in the cationexchange step using a buffer containing a compound having a specificaffinity for albumin, especially an acid or salt thereof, for exampleoctanoate or any other long chain (C₆-C₂₂) fatty acid, salicylate,octylsuccinate or N-acetyltryptophan.

Suitably, the albumin is eluted from the anion exchanger with a buffercontaining a high level (eg at least 50 mM, preferably 50-200 mM, forexample 80-150 mM) of a boric acid salt, for example sodium or potassiumtetraborate.

The albumin purified in accordance with the invention may then, with orwithout intervening process steps, be subjected to chromatography on aresin containing an immobilised compound which will selectively bindglycoconjugates and saccharides, such as aminophenylboronic acid (PBA).

In any process of the invention which involves affinity chromatography,the affinity chromatography preferably uses a resin comprising animmobilised albumin-specific dye, such as a Cibacron Blue type of dye,preferably immobilised on the resin via a spacer such as1,4-diaminobutane or another spacer of C₁₋₈, preferably C₁₋₆, eg C₁₋₅and most preferably C₄ length, preferably having α,ω-diaminosubstitution. Surprisingly, we have found that such dyes actually have agreater affinity for a 45 kD albumin fragment which can be produced incultures of HA-secreting microorganisms, than they do for the fulllength albumin molecule. The 45 kD fragment typically consists of the1-403 to 1-409 region and is disclosed in Sleep et al (1990)Bio/Technology 8, 42-46 and in WO 95/23857.

The purified albumin solution prepared by the process of the inventionmay be further processed according to its intended utility. For example,it may be ultrafiltered through an ultrafiltration membrane to obtain anultrafiltration retentate having an albumin concentration of at leastabout 80 g albumin per liter, with the ultrafiltration retentate beingdiafiltered against at least 5 retentate equivalents of water. It can beadvantageous to include ammonium ions in certain chromatographic steps,for example in the step involving immobilised aminophenylboronate.Surprisingly, we have found that such ammonium ions are relativelytightly bound to the albumin. It is preferable for such ammonium ions tobe removed from the albumin and we have found that this can be achievedby use of a counter-ion. The desirability of exposing the albumin to acounter-ion would not have occurred to those in this art since priorprocesses have not involved ammonium ions and there was no reason tosuppose that ammonium ions would be bound by the albumin.

Accordingly, a further aspect of the invention provides a method ofpurifying an albumin solution comprising exposing the solution to asolution of a counter-ion such that ammonium ions are displaced from thealbumin and can be removed from the solution.

The counter-ion (preferably a metal ion such as sodium ions) can beadded to the albumin solution and the ammonium ions removed by dialysis,or the ammonium ion can be diafiltered away across a semi-permeablemembrane separating the albumin from the solution of the counter-ion, orthey can be removed by gel permeation chromatography. Diafiltrationagainst at least five retentate volumes of 50 mM sodium chloride isgenerally suitable.

The albumin obtained has been found to have extremely low levels of, orto be essentially free of, colorants, lactate, citrate, metals, humanproteins such as immunoglobulins, pre-kallikrein activator, transferrin,α₁-acid glycoprotein, haemoglobin and blood clotting factors,prokaryotic proteins, fragments of albumin, albumin aggregates orpolymers, endotoxin, bilirubin, haem, yeast proteins and viruses. By“essentially free” is meant below detectable levels. The term “colorant”as used herein means any compound which colours albumin. For example, apigment is a colorant which arises from the organism, especially yeast,which is used to prepare recombinant albumin, whereas a dye is acolorant which arises from chromatographic steps to purify the albumin.At least 99%, preferably at least 99.9%, by weight of the protein in thealbumin preparations purified by the process of the invention isalbumin. Such highly pure albumin is less likely to cause adverse sideeffects.

The albumin produced by the process of the invention has been found tobe at least 99.5% monomeric, preferably substantially 100% monomeric byreducing SDS PAGE, and is characterised by one or more of the followingcharacteristics. It has an aluminium ion content of less than 150 ng,preferably less than 100 ng; an iron ion content of less than 3,000 ng,preferably less than 1,000 ng; a copper ion level of less than 10,000ng, preferably less than 5,000 ng; a magnesium ion level of less than3,000 ng, preferably less than 1,500 ng; a zinc ion level of less than5,000 ng, preferably less than 3,000 ng, a manganese ion level of lessthan 50 ng, all based on one gram of albumin; a glycation level of lessthan 0.6, preferably less than 0.15 (more preferably less than 0.05),moles hexose/mole protein; a level of low molecular weight contaminantsof below 20 V·sec, preferably less than 10 V·sec, measured as in Example9 below; a single peak on a capillary zone electrophoretogram; intact,ie homogeneous, C-terminus and N-terminus; a free thiol content of atleast 0.85 mole SH/mole protein; and no more than 0.3 mol/mol of C10 toC20 fatty acids and substantially no C18 or C20 fatty acids.

The starting material may be an albumin-containing fermentation medium,or the impure albumin solution may be a solution obtained from serum byany of the plethora of extraction and purification techniques developedover the last 50 years, for example those disclosed in Stoltz et al(1991) Pharmaceut. Tech. Int. June 1991, 60-65 and More & Harvey (1991)in A Blood Separation and Plasma Fractionation≅Ed. Harris, Wiley-Liss,261-306.

Especially when the albumin is rHA produced in protease-deficient yeastsor other organisms, the process does not normally comprise a heattreatment step as part of the purification process (in contrast to EP428 758 and EP 658 569). Similarly, if it is prepared frommicroorganisms (rather than from humans) it does not normally require afinal pasteurisation step (typically 60° C. for one hour).

The final product may be formulated to give it added stability.Preferably, the highly pure albumin product of the invention contains atleast 100 g, more preferably 1 kg or 10 kg of albumin, which may besplit between a plurality of vials.

Although the process of the present invention can be utilised to obtainmore purified albumin from an impure albumin solution from a number ofsources, such as serum, it is particularly applicable to purifyingrecombinant human albumin (rHA). The albumin produced in accordance withthe invention may be any mammalian albumin, such as rat, bovine or ovinealbumin, but is preferably human albumin. DNA encoding albumin may beexpressed in a suitable host to produce albumin. Thus, DNA may be usedin accordance with known techniques to construct an expression vector,which is then used to transform an appropriate host cell for theexpression and production of albumin. Such techniques, include thosedisclosed in EP-A-73 646, EP-A-88 632, EP-A-201-239 and EP-A-387 319.

Many expression systems are known, including bacteria (for example E.coli and Bacillus subtilis), yeasts (for example Saccharomycescerevisiae, Pichia pastoris and Kluyveromyces lactis), filamentous fungi(for example Aspergillus), plant cells, animal cells and insect cells.The preferred microorganism is the yeast Saccharomyces cerevisiae.

Exemplary genera of yeast contemplated to be useful in the practice ofthe present invention are Pichia (Hansenula), Saccharomyces,Kluyveromyces, Candida, Torulopsis, Torulaspora, Schizosaccharomyces,Citeromyces, Pachysolen, Debaromyces, Metschunikowia, Rhodosporidium,Leucosporidium, Botryoascus, Sporidiobolus, Endomycopsis, and the like.Preferred genera are those selected from the group consisting of Pichia(Hansenula), Saccharomyces, Kluyveromyces, Yarrowia and Hansenula.Examples of Saccharomyces spp are S. cerevisiae, S. italicus and S.rouxii. Examples of Kluyveromyces spp. are K. fragilis and K. lactis.Examples of Pichia (Hansenula) are P. angusta (formerly H. polymorpha),P. anomala, P. pastoris and P. capsulata. Y. lipolytica is an example ofa suitable Yarrowia species.

It is advantageous to use a yeast strain which is deficient in one ormore proteases. Such strains include the well-known pep4-3 mutants andstrains with mutations in the PRA1 and/or PRB1 genes, as in Woolford etal (1993) J. Biol. Chem. 268, 8990-8998, Cabezón et al (1984) P.N.A.S.81, 6594-6598, EP-A-327 797 and Jones et al (1982) Genetics 102,665-677. Alternatively, the proteases in the fermentation medium may beinactivated by heating. The existence of proteases reduces the yield ofthe albumin during the overall process.

Preferably, the yeast has a low (or zero) level of the Yap3p proteaseand/or of the hsp150 heat shock protein, for example as a result ofhaving the respective genes disrupted, as is taught in our patentapplications published as WO 95/23857 and WO 95/33833, respectively.Yap3p can cause the formation of the 45 kD albumin fragment referred tobelow, and hsp150 co-purifies with albumin in some separation steps.

Yeast may be transformed with an expression plasmid based on theSaccharomyces cerevisiae 2 μm plasmid. At the time of transforming theyeast, the plasmid contains bacterial replication and selectionsequences, which may be excised, following transformation, by aninternal recombination event in accordance with the teaching of EP 286424. The plasmid may also contain an expression cassette comprising: ayeast promoter (such as the Saccharomyces cerevisiae PRB1 promoter), astaught in EP 431 880; a sequence encoding a secretion leader, forexample one which comprises most of the natural HSA secretion leader,plus a small portion of the S. cerevisiae α-mating factor secretionleader, as taught in WO90/01063; the HSA coding sequence, obtainable byknown methods for isolating cDNA corresponding to human genes, and alsodisclosed in, for example, EP 73 646 and EP 286 424; and a transcriptionterminator, for example the terminator from Saccharomyces ADH1, astaught in EP 60 057.

The choice of various elements of the plasmid described above is notthought to be directly relevant to the purity of the albumin productobtained, although the elements may contribute to an improved yield ofproduct.

Preferred aspects of the invention will now be described by way ofexample and with reference to the accompanying drawings, in which:

FIG. 1 shows schematically a fermenter used to produce rHA;

FIG. 2 is a UV trace from a C18 PTH Reverse Phase HPLC column (AppliedBiosystems Inc), showing the low level of low molecular weightcontaminants in the albumin of the invention;

FIG. 3 is similar to FIG. 2 but shows low molecular weight contaminantsin prior art albumin;

FIG. 4 is a gas chromatogram showing the fatty acid content ofcommercially available albumin;

FIG. 5 corresponds to FIG. 4 but shows albumin of the invention; and

FIGS. 6 a and 6 b show electrospray mass spectrometry for albumin of theinvention and prior art albumin, respectively.

EXAMPLE 1 Preparation of Impure Albumin Solution

The cloning strategy for construction of the albumin-producingmicroorganism was as disclosed in EP 431 880. Plasmid pAYE316 wasintroduced into a (MATa, leu2, pep4-3, [cir/]) Saccharomyces cerevisiaestrain by the method described by Hinnen et al, (1978) P.N.A.S. 75,1929. Transformants were selected on a minimal medium lacking leucine(Yeast nitrogen base, Difco). When transformants were grown for 72 hoursat 30° C., 200 rpm in 50 ml flasks containing either 10 ml of complex(YEP, 1% (w/v) yeast extract, 2% (w/v) bactopeptone and 2% (w/v)sucrose), or defined (0.15% (w/v) yeast nitrogen base without aminoacids and ammonium sulphate, 0.5% (w/v) ammonium sulphate, 0.1M citricacid/Na₂HPO₄.12H₂O pH6.5, 2% (w/v) sucrose) liquid medium, rHA could bedetected in the cell free culture supernatant by SDS-polyacrylamide gelelectrophoresis and/or by rocket gel immunoelectrophoresis.

A stock master cell culture in defined liquid medium (Buffered MinimalMedium (BMM) salts medium: Yeast Nitrogen Base [without amino acids and(NH₄)₂SO₄, Difco], 1.7 g/L; citric acid monohydrate 6.09 g/L; anhydrousNa₂HPO₄, 20.16 g/L, pH 6.5±0.2, sucrose is added to 20 g/L) is used toprepare running stocks (manufacturer's working cell bank) of processyeast suitable for the preparation of shake flask cultures by freezingaliquots of the culture in the presence of 20% (w/v) trehalose.

Fermentation

This section relates to the production of rHA from stock culture throughto the final fermentation and is a general definition of an rHAfermentation process which is not limited to the specific detail ofparticular equipment or scale.

Shake Flask Culture. The yeast [cir^(o), pAYE316] is grown as an axenicculture physiologically suited for inoculation of the seed vessel. Iftiming of the seed vessel is to be reproducible, it is necessary todefine the phase of growth (primary carbohydrate excess) and inoculumbiomass (12±2 mg/L which requires a 100 ml inoculum per 10 liters ofmedium). One stock vial is inoculated into a shake flask containing 100mL of BMM +2% (w/v) sucrose and the flask is incubated at 30° C. on anorbital shaker (200 rpm revolutions per minute) until a cell dry weight(cdw) of 0.6-1.2 g/L (assessed by optical density at 600 nm) isobtained. This culture is then used to inoculate a seed fermentationvessel to a level of 12±2 mg/L.

Seed Fermentation. The inoculum for the main production fermenter isprovided by growing the production organism, preferably S. cerevisiae[cir^(o), pAYE316], in a seed fermenter (in this example, 20 L workingvolume) to a high cell dry weight (cdw) of approx. 100 gL⁻¹. A fed-batchregime is followed so as to minimise the accumulation of ethanol andacetate and thus to maximise cell yield. The whole of each fermentationis monitored and controlled via a computer control system, such as theMulti-Fermenter Computer System (MFCS) software available from B. Braun(Germany). The software supplied by B. Braun is a Supervisory Controland Data Acquisition Package; similar packages are available from othercompanies. The feed control algorithm is intended to control theaddition of sucrose so that maximum biomass is achieved by avoiding theCrabtree effect, thereby minimising the production of ethanol and/oracetate. The fermentation vessel is subjected to a hot NaOH wash andpyrogen-free water (PFW) rinse. The heat sterilised vessel will containapproximately 10 L of sterile MW 10 medium (Table 1) batch salts plustrace elements. The medium for rHA production can be ultrafiltered(10,000 Mol. Wt. cut-off) to remove endotoxins.

TABLE 1 MW10 MEDIUM Batch Feed Constituents Medium Medium Salts KH₂PO₄2.74 g/L 10.9 g/L MgSO₄•7H₂O 0.58 g/L 2.3 g/L CaCl₂•2H₂O 0.06 g/L 0.24g/L H₃PO₄ (85% w/w) 0.88 ml/L 1.76 ml/L Vitamins Ca pantothenate 20 mg/L180 mg/L Nicotinic acid 33.3 mg/L 300 mg/L m-Inositol 20 mg/L 180 mg/Ld-biotin 0.133 mg/L 0.8 mg/L Thiamine•HCl 16 mg/L 32 mg/L Trace elementstock* 10 ml/L 20 ml/L Sucrose 0** 500 g/L *Trace Element StockConstituents ZnSO₄•7H₂O 3 g/L FeSO₄•7H₂O 10 g/L MnSO₄•4H₂O 3.2 g/LCuSO₄•5H₂O 0.079 g/L H₃BO₃ 1.5 g/L KI 0.2 g/L Na₂MoO₄•2H₂O 0.5 g/LCoCl₂•6H₂O 0.56 g/L The trace elements are added to demineralised water,acidified with 35 ml/L of 98% H₂SO₄. **20 g Sucrose/L is added to thebatch medium at the 20 L seed fermenter stage. Any convenient method ofsterilisation may be used, as may any depyrogenation method, for exampleultrafiltration. The vitamins are always filter sterilised.

After the medium is added to the vessel, the operating temperature of30° C. is set, as well as the minimum stirrer speed, typically 400-500rpm. The initial pH is adjusted with ammonia solution (specific gravity0.901) using a pH controller set at 5.7±0.2. 2M H₂SO₄ is also used as apH corrective agent. Sucrose to 20 gL⁻¹, MW10 batch vitamins, and BreoxFMT30 antifoam to 0.04 gL⁻¹ are added to the vessel.

Sterile filtered air is introduced into the vessel at 0.5 v/v/m (ie 0.5liter non-compressed air per liter of medium per minute), the medium isinoculated to 12±2 mg cell dry weight L⁻¹ from an axenic shake flaskculture and the MFCS computer system is initiated. Following completionof the batch phase of growth (signalled by a dissolved oxygen tensionincrease of >15% in 30 min), addition of the feed medium is initiated,under control of the MFCS system. The control strategy is effectivelythe same as described below for the production fermentation. During thefermentation the air flow is increased in two steps in order to maintaina flow of approximately 1 v/v/m. The dissolved oxygen tension (DOT) iscontrolled at 20% air saturation by changing the stirrer speed. Once thestirrer speed cannot be increased further and the air flow rate hasreached its maximum value, the feed control algorithm controls the feedrate to minimise the formation of fermentation products. At the end ofthe feed, the culture is transferred to a production vessel.

Production Fermentation. An axenic culture of the yeast [cir/, pAYE316]is produced by fed-batch fermentation to a high cdw (>80 gL⁻¹) for theproduction of extracellular rHA. The production fermenter, in thisexample a fermenter with a working volume of 8,000 L, is inoculated withthe culture grown in the seed fermenter, the cell dry weight of which ispreferably >80 g·L⁻¹. The initial cell dry weight concentration in theproduction fermenter on transfer of the seed fermenter culture ispreferably 0.25-1.00 g·L⁻¹. Although it is preferred to initiate feedingwithin one hour, it can be delayed if necessary. Due to the very lowvalues of OUR and CER during the initial part of the feed phase and theconsequent errors in their measurement, the automatic control of feedrate using RQ is initially disabled. The feed regime is intended tominimise the accumulation of ethanol and acetate, so as to maximise thecell and product yield.

The fermentation is carried out in a fermenter such as that shown inFIG. 1, designed to give optimum gas dissolution and bulk mixing. Thevessel, which is subjected to a hot NaOH wash and PFW rinse, willcontain approximately 4000 L of sterile MW10 (Table 1), batch salts andtrace elements. This medium may be sterilised independently of thevessel either by heat or filter sterilisation. It has been found inaccordance with the present invention that it is advantageous for thefermentation medium, such as MW10, to be free of ethylene diaminetetraacetic acid (EDTA), or a salt thereof or other strongmetal-chelating agents, since their presence results in a significantlyhigher degree of coloured contaminants in the albumin produced.

The operating temperature is set at 30° C., and the stirrer speedregulated to be sufficient to maintain a homogeneous solution, typicallyabout 50 rpm. The initial pH is adjusted with ammonia solution (SG0.901) (controller set to 5.7±0.2). 2M H₂SO₄ may be used as a second pHcorrective agent. The MW10 batch vitamins are added, as is a suitableantifoam, as required (eg Breox FMT3 0 to 0.125 gL⁻¹).

Sterile filtered air is added to the vessel at 0.5 v/v/m initially tomaximise sensitivity of exhaust gas analysis, and the MFCS computersystem is initiated. The exhaust gas is analysed, for instance by use ofa continuous mass spectrometer (eg a Fisons VG gas analyzer). The vesselis inoculated with the whole of the seed vessel culture (minimum 0.4%v/v). MW10 feed in a volume equal to the batch volume. The feed isstarted and the RQ override control disabled until OUR and CER valuesare sufficiently high to make control effective. The feed rate isadjusted manually during the period without RQ control if RQ isconsistently >1.2. The feed rate is increased, via computer control,according to the following algorithm:Feed rate(FR)=ke ^(μt)where k is the initial feed rate, μ is the exponential growth rate, andt is time. The value k is determined empirically as the initial feedrate that is necessary to achieve a growth rate that minimises theaccumulation of ethanol and acetate. For this example, k has beendetermined as having a value 0.08 mL of MW10 feed medium per minute perliter of culture. The value μ is related to the maximum growth rate of afully respirative organism, in this example 0.1 h⁻¹.

t is a counter variable that starts at 0 (zero) and then increases by 1every minute, unless RQ>1.2 or DOT<15%. In these cases, the value of tis reduced.

The vessel can be overpressured as necessary to enhance OTR. The cultureis held for downstream processing at the end of the feed.

This hold time should be kept to a minimum, but can be extended up to 48hours and beyond if necessary. During the hold phase, the temperature ofthe culture is reduced to the minimum possible, typically between 4 and15° C., preferably 4° C., and the DOT is allowed to fall to 0%. The feedis stopped, the aeration turned off and the overpressure reduced. The pHcontrol, however, is maintained. Sufficient agitation is maintained toretain the cells in suspension and facilitate cooling and pHhomogeneity, preferably about 50 rpm.

The expected yields in accordance with the above procedure are:biomass>80 g cell dry weight/L culture; rHA>1.5 g monomer/L culture(determined by SDS-PAGE, related to the whole culture).

In order to prepare an impure albumin solution for purificationtreatment in accordance with the present invention when the albumin isrHA, the microorganism cells are removed from the fermentation culturemedium. While it is preferred that the cells be removed prior tobeginning of the purification process as described, it can be carriedout simultaneously with the first step under certain conditions, egwhere the first purification step is carried out in a fluidised bed. Thefermentation culture, which has been cooled in the fermenter during thehold phase to less than 15° C. without aeration, is transferred to atank where it is diluted to give a biomass concentration of 180-210 g/kgand cooled further if necessary. The diluted culture should be held foras short a time as possible without aeration at reduced temperature withsufficient agitation to prevent yeast cell deposition.

Cells and supernatant are subjected to a primary separation step, forexample microfiltration or centrifugation in any appropriate centrifugesuch as an Alfa Laval BTUX510 continuous discharge nozzle run at 5700rpm. Centrate so produced may be filtered in line, for example using adepth filter (1 μm pore size), supplied by Cuno, to remove residualwhole and broken yeast cells and other particles. At least 75% of therHA present in the diluted culture is recovered in a single passcentrifugation operation. Optionally, the cell slurry from thisoperation may be resuspended in water or buffer and re-centrifuged toprovide a second centrate, thus enhancing product recovery. Theresultant solution is then treated by the process of the invention topurify the albumin contained therein as shown in Example 2.

EXAMPLE 2 Purification of Albumin in Accordance with the Invention

The centrate from a fermentation (such as described in Example 1), or animpure albumin solution from any other source (such as plasma), isprepared, or conditioned, for chromatography on a cation exchange matrixwhile protecting the albumin from polymerisation (by includingoctanoate) and protease activity (by heating or by choosing yeastwithout damaging levels of proteases). Preferably, sodium octanoate isadded (Chromatography Solution 13 (CS13)—Table 2) to a finalconcentration of 1-10 mM, for example approximately 5 mM, to stabilisethe albumin. The pH is adjusted with acetic acid (CS09) to 4.3-4.8,preferably 4.50±0.1 (most preferably ±0.05), and the conductivity ischecked to be <5.5 mS cm⁻¹.

The culture supernatant from some host strains or species containsproteases that can degrade rHA during subsequent processing. In suchinstances, this protease activity can be destroyed by heat treatment ofthe culture supernatant containing the rHA. Typically 1-10 mM sodiumoctanoate is sufficient to protect the rHA from heat denaturation, and30 seconds up to 10 minutes at temperatures of 60-80° C. is adequate toinactivate the proteases. Subsequently the supernatant can be furtherconditioned as described previously. If degradation by proteases is notencountered, then the heat treatment is preferably omitted.

Chromatography

All operations can be carried out at ambient temperature (20±5° C.). Thealbumin loads (g albumin/L matrix) for the chromatography columns aredetermined from titres of albumin (g/L) by either SDS-PAGE (in the caseof the SP-FF column) or GP-HPLC (for all other columns). The progress ofeach step is monitored by measuring UV absorbance on line, for exampleat 254 or 280 nm.

The sequence of chromatographic steps as described here is novel andinventive in a number of aspects. The use of a cationic matrix for thefirst purification step allows the majority of low molecular weightpigmented species derived from the yeast fermentation to pass directlythrough the column, whereas those that do bind to the matrix are boundweakly and can be removed by a high ionic strength salt clean such as 1MNaCl. Thus the cationic matrix, unlike an anionic matrix which adsorbsthese type of molecules irreversibly, can be regenerated and used formultiple cycles of chromatography as the first step in the purification.Hence, this step forms the basis for a robust commercial chromatographyprocess.

The use of a Cibacron Blue type of column as the second step in thisexample is novel in that it is used specifically to remove a 45 kDafragment of albumin which is very difficult to remove from albumin asits physicochemical properties, eg size and pI, are similar to theintact molecule. Surprisingly, the fragment binds more strongly to thedye than full length albumin does, thus allowing their separation.

The chromatography solutions used during the purification of albumin aredetailed in Table 2. Because of the very large scale manufacture ofalbumin, and the relatively low cost of the product, these buffer saltsare the most suitable for the process as they are available in a highlypure form at industrial scale and are low cost compared to othercommonly used buffers such as Tris, HEPES or MOPS. Alternative bufferscould be used in place of the ones used in Table 2, for example buffersof a similar pK_(a) (eg malate for acetate), but in most instances costand availability at large scale rule out their use. Alternative saltforms can be used provided they are soluble, available at industrialscale and low cost. However, the inclusion of tetraborate ions in CS06and CS10 is particularly advantageous since they perform a specific rolein complexing with carbohydrate moieties in macromolecules and bindingthem tightly to the anionic groups on the matrix. This results in anenhanced purity of albumin in the eluate.

Chromatography can be performed using either axial flow columns, such asthose available from Pharmacia, or using radial flow columns, such asthose available from Sepragen. In this example, the columns are allaxial.

The buffer solutions can be prepared at the concentrations describedbelow, or concentrated stock solutions can be prepared and mixed ordiluted on-line for immediate use.

TABLE 2 CHROMATOGRAPHY SOLUTIONS FOR THE PURIFICATION OF ALBUMIN INEXAMPLE 2 Solution Constituent Concentration (gL⁻¹) pH Conductivity (mScm⁻¹) CS01 SP-FF Equilibrant CH₃COONa•3H₂O 3.69 5.45-5.65 1.9-2.2CH₃COOH (glacial) 0.220 CS02 SP-FF Eluent CH₃COONa•3H₂O 13.6 5.45-5.656.5-7.5 CH3COOH (glacial) 0.750 CS03 DBA Eluent NaCl 117 9.0-9.4 125-165CH₃COONH₄ 3.84 NaOH 0.680 CS04 0.5M NaOH NaOH 20.0 >12  80-120 CS05 GelPermeation CH₃COONa•3H₂O 4.94 5.4-5.6 2.9-3.3 CH₃COOH (glacial) 0.380Octanoic Acid 0.721 NaOH 0.190 CS06 DE-FF Eluent Na₂B₄O₇•10H₂0 7.628.9-9.3 11.7-13.5 NaCl 5.84 CS07 20 mM NaOH NaOH 0.800 >12 3.5-5.5 CS08DE-FF Equilibrant CH₃COONa•3H₂O 4.94 5.4-5.6 2.9-3.3 CH₃COOH (glacial)0.380 Octanoic Acid 0.721 NaOH 0.190 CS09 Acetic Acid CH₃COOH Glacial —— CS10 DE-FF Wash Na₂B₄O₇•10H₂0 7.62 9.0-9.4 2.3-2.9 CS11 DE-FF Pre-CH₃COONa•3H₂O 61.8 5.5-5.7 24-28 equilibrant CH₃COOH (glacial) 2.98 CS12DBA Equilibrant/ NaCl 11.7 8.8-9.2 18-22 Wash CH₃COONH₄ 0.960 NaOH 0.150CS13 2M Sodium Octanoic Acid NaOH 288 7.7-8.2 — Octanoate 76.0 CS141.73M H₃PO₄ (85% 200   <1.2 — Phosphoric acid (w/w)) CS15 2M AmmoniaNH₄OH (30% NH₃ 113 ml — — (w/w)) All weighings are ∀ 2%, for thisparticular example.

Cation Exchange Chromatography. Albumin is concentrated and purifiedwith respect to at least yeast proteins (if the albumin is rHA from ayeast fermentation) and other antigens, low molecular weightcontaminants and pigmented compounds by cation exchange chromatography.The method uses a commercial cation exchange matrix such as SP-SepharoseFF, SP-Spherosil, CM-Sepharose FF, CM-Cellulose, SE-Cellulose orS-Spherodex. Preferably the matrix is SP-Sepharose FF (Pharmacia) at abed height of 5 to 25 cm, preferably 10 to 15 cm and in this example12.5 cm, with a column loading of 10 to 50 g albumin/L, preferably 40±10g albumin/L matrix. The matrix is equilibrated with a buffer to removethe alkali storage solution; preferably the buffer should be strongenough to reduce the pH to approximately pH6.0. A buffer such as CS01 isused to remove storage solution CS07 from the column; however, anybuffer with a pH<6.0 could be used. Equilibration is judged to becomplete when the pH of the column effluent is approximately pH6.0.

The conditioned centrate is then loaded onto the column at a flow rateof, for example 1.0-8.0 cm/min, preferably 4.0-7.0 cm/min, in thisexample, 6.36 cm/min, and then the column is washed with a solution toremove residual contaminants. This wash solution should have a pH<6.0and a conductivity less than 5 mS cm⁻¹, preferably less than 3 mS cm⁻¹,to prevent the elution of albumin. A suitable solution is CS01. Thepreceding steps are all run at 6.36 cm/min; for elution and allsubsequent steps the flow rate is reduced to 0.5-5.0 cm/min, preferably2.0-4.0 cm/min, in this example 3.18 cm/min, in order to reduce thevolume of eluate. Elution of albumin is effected by increasing the ionicstrength; a solution with a conductivity in the range 5-10 mS cm⁻¹,preferably 6-8mS cm⁻¹, for example CS02, is used. The collection ofalbumin starts when the UV signal rises above 1.0 A₂₈₀/cm, andcollection continues until the WV signal falls below 0.6 A₂₈₀/cm or amaximal volume of 6.5 column volumes has been collected. The column isthen cleaned using CS03 and 04, and then stored in CS07.

Affinity Chromatography. This step further purifies the albumin withrespect to a 45 kDa N-terminal albumin fragment, yeast antigens (if thealbumin is rHA from a yeast fermentation) and pigment. The affinitymatrix may comprise any Cibacron Blue type of dye which binds albumin,for example Reactive Blue 2, Procion Blue HB, Blue Sepharose, BlueTrisacryl and other anthraquinone-type compounds. Preferably, the matrixis the A Delta Blue Agarose≅matrix described below. This been found toreduce the levels of Blue leachates generated by the matrix and toenhance the alkaline stability of the matrix to facilitate cleaning anddepyrogenation. A further improvement of the matrix compared tocommercially available matrices is the incorporation of a spacer,1,4-diaminobutane, between the dye (Reactive Blue 2) and the matrix.This was found to be the optimal length of spacer with respect to eluatealbumin purity.

Reactive Blue 2 has the chemical structure represented below.

The ortho, meta or para isomer, or any mixture thereof, can be used. Thepreferred isomer is the ortho-SO³⁻ form but, as it is difficult to maketo the desired purity, the meta isomer is used. The aminobutyl-ReactiveBlue 2 is prepared to a minimum purity of 98% total peak area asdetermined by analytical HPLC. This can be achieved either by usingcrude commercially available dye, which will necessitate purification ofthe aminobutyl derivative dye, or using a pure synthesised dye. In thelatter method, the starting dye material should be a minimum of 98% pureby analytical HPLC at 280 nm. Such material is available from ACL, Isleof Man. Reactive Blue 2 is reacted with 1,4-diaminobutane in water byheating the mixture to 60° C., after which the derivatised dye ispurified from the mixture, for instance by precipitation. Theaminobutyl-Reactive Blue 2 is then coupled to the matrix, for instanceto epichlorhydrin-activated Sepharose CL-6B (Pharmacia, Sweden). SeePorath et al (1971) J. Chromatog. 60, 167-177. The dye content of such aDelta Blue Agarose (DBA) matrix should, preferably, be 50±5 mmole/g dryweight.

Use of Blue Matrix. The method uses DBA at a bed height of 10-30 cm,preferably 20-30 cm (in this example 25 cm), with a column loading of7-14 g rHA/1 matrix, preferably 8-12 g/l (in this example 10±1 galbumin/L matrix); all steps are run at a flow rate of 0.3-2.0 cm/min,preferably 1.0-2.0 cm/mm, in this example 1.53 cm/min. The DBA isequilibrated in CS01 from CS07; equilibration is complete when the pH ofthe column effluent is approximately pH9.5. Prior to chromatography, theSP-FF eluate is adjusted to approximately pH8.5-9.5, preferably pH 9.0,with ammonia, and then loaded onto the column. When loading is complete,the column is washed to remove contaminants with 1-5 volumes of buffer10-30 mS cm⁻¹, preferably 15-25 mS cm⁻¹, for example CS12, preferably 5column volumes. The albumin is eluted using a high ionic strength bufferof >100 mS cm⁻¹, preferably 125-165 mS cm⁻¹, for example CS03. Eluatecollection is started when the UV signal (A₂₈₀/cm) rises above 0.4, andstops when the signal falls below 0.4 again. The column is then cleanedusing CS04 and stored in CS07.

Intermediate Ultrafiltration. This step concentrates the albumin for gelpermeation chromatography. A cellulose-type membrane (nominal molecularweight cut off less than or equivalent to 30,000, for example 10,000) inan ultrafiltration apparatus is used to concentrate DBA eluate to aretentate concentration of 20-120 g/L albumin, preferably 80-110 g/L.The membranes are treated, post-use, by flushing out residual proteinwith water, or CS03 or CS05 from Table 3, and cleaning with 0.1M sodiumhydroxide. The membranes may then be stored in 20 mM sodium hydroxide.

Gel Permeation Chromatography. This step purifies the albumin withrespect to yeast antigens (if the albumin is rHA from a yeastfermentation), pigment and dimerised albumin and performs a bufferexchange step. The method uses a commercial gel permeation matrix suchas Sephadex G100, G150, G250, Sephacryl S-100, S-200 or S-300, ToyopearlHW50S or Superose 6 or 12. Preferably, the matrix is Sephacryl S-200 HR(Pharmacia) at a bed height of greater than 60 cm, preferably 90 ∀cm(3×30 cm). The column is equilibrated in CS05 and run at 0.1-1.5 cm/min,preferably 0.5-1.0 cm/min, in this example 0.75 cm/min; the column isthen loaded with albumin from the intermediate UF step when pH 9.5 isreached. The load volume is equivalent to approximately 2-9% of thecolumn volume, preferably 5-8%, for example 7.5% of the column volume.The albumin fraction is collected in three parts: an initial smallamount of albumin dimer goes to waste until the A₂₈₀/cm reaches 10% fullscale deflection (FSD) on the way up; at this point collection of arecycle fraction starts and continues until 90% FSD and then the albuminis collected as the primary product fraction. This continues until theA₂₈₀ falls through 5% FSD, after which the effluent stream is directedto waste again. The recycle and primary product fractions are collectedseparately. This step is repeated until all the material has been loadedonto the column.

S-200 HR Recycle Ultrafiltration. A cellulosic type membrane, nominalmolecular weight cut-off equal to or less than 30,000, or as used inthis example 10,000, in an ultrafiltration apparatus, is used toconcentrate the pooled recycle fraction to a retentate concentration of20-120 g/L albumin, preferably 80-110 g/L. The membranes are treated,post-use as described above under Intermediate Ultrafiltration.

Alternatively, as in any ultrafiltration steps in this process,polyethersulfone or PVDF membranes with a cut-off of #30,000 may be usedinstead of the cellulose-type membranes. Such membranes are availablefrom Amicon and Millipore. It is preferable to use membranes which arecompatible with NaOH, used for storage and cleansing of the membranes.

Purification of S-200 HR Recycle Ultrafiltration Retentate. Theretentate from recycle ultrafiltration is loaded onto the same column asused for the primary S-200 purification and a product fraction collectedfrom each peak, which is then mixed with the bulked primary productfractions collected previously. This step is repeated until all thematerial has been loaded onto the column.

Anion Exchange Chromatography. The aim of this step is to purify albuminwith respect to at least yeast antigens (if the albumin is rHA from ayeast fermentation) and pigmented albumin. The method uses an anionexchange matrix such as QMA-Spherosil, DEAE-Spherodex, Q-Hyper D,DEAE-cellulose, QAE-cellulose, or TMAE, DMAE, or DEAE Fractogel.Preferably, the matrix is the commercial anion exchange matrix DEAESepharose-FF (Pharmacia) at any convenient bed height in the range 5-25cm, preferably 10-15 cm, for example 12.5 cm, with a column loading of10-60 g albumin per liter of matrix, preferably 35∀15 g/L matrix. Thecolumn is first equilibrated in a strong buffer to bring the pH down tothe working range quickly, eg sodium acetate pH 4.5-6.0, preferablyapproximately pH5.5, for example CS11. After the concentrated buffer, asolution of lower conductivity, namely in the range 1-4 mS cm⁻¹,preferably 2.5-3.5 mS cm⁻¹, for example CS08, is used to equilibrate thecolumn prior to loading the column with S200 eluate. A linear flow rateof 1.0-8.0 cm/min, preferably 3.0-7.0 cm/min, in this example 4.4 cmmin⁻¹, can be used. When loading is complete, the column is washed witha solution of sodium tetraborate in the range 5-30 mM, preferably 15-25mM, for example CS10. This causes any carbohydrate-containingcontaminants to adhere to the column more strongly prior to elution ofthe albumin fraction. Elution can be effected by any high ionic strengthsolution in the range 10-20 mScm⁻¹, preferably with CS06. The eluate iscollected when the A₂₈₀/cm reaches 0.4, and continues until the peakfalls through 0.8.

Hence, in this example, the sequence of purification steps is: cationexchange, affinity chromatography, ultrafiltration, gel permeation (withultrafiltration of recycle fraction) and anion exchange.

The eluate from the DE-FF column has been found to have less than 0.1%(w/w) albumin dimer and an undetectable level of albumin polymers oraggregates as analysed by GP HPLC using a TSK SW3000XL column, loadedwith 25.0 μl of eluate containing 10.0 mg/ml of albumin.

EXAMPLE 3 Formulation of Purified Albumin into a Final Product

This Example illustrates the concentration, diafiltration andformulation of the highly purified albumin into a suitable product, inthis instance 25% (w/v) albumin. This procedure is carried out in twostages, namely final ultrafiltration (UF) and formulation. Final UFbegins with transfer of the DEAE eluate (adjusted to pH 7.0±0.3 withphosphoric acid) to the Final UF feed vessel and terminates afterretentate and washings, if any, are transferred to the formulationvessel. The albumin-containing process stream is sequentially subjectedto primary concentration, diafiltration and secondary concentration inan ultrafiltration system fitted with cellulosic or, more preferably,polyethersulphone membranes with a nominal molecular weight cut offlimit of 10,000. The initial concentration step increases the albuminconcentration to approximately 100 g·L⁻¹ and is immediately followed bythe continuous diafiltration phase where the albumin is diafilteredagainst at least 5, preferably at least 7, retentate volume equivalentsof water-for-injection.

In some purification processes of the invention, for example the stepset out in Example 7 using immobilised aminophenylboronate, ammoniumions may be present at this stage. Surprisingly, we have found thatthese ammonium ions are bound quite tightly by the albumin and cannot becompletely removed by diafiltration against water. We have found thatdiafiltration against a salt solution is effective. A ratio of 0.5 to10% w/w of sodium chloride to albumin, for example 1.0 to 5.0% or about3%, may be used. The salt may be added to the albumin retentate or, moreusually, will be added to the diafiltration water. For an ultimate 5%(w/v) formulation, a solution of approx 100 g/l may be recovereddirectly from the diafiltration step. For an ultimate 25% (w/v)formulation, a solution of approx 275-325 g/l is obtained following afurther concentration step (UF). Finally, the solution is transferred tothe bulk product formulation vessel.

The formulation step produces albumin in an appropriate chemicalenvironment and at an appropriate concentration suitable for bulkproduct sterile filtration (0.22 μm hydrophilic,polyvinylidene-difluoride) and filling. The transferred solution isanalysed to determine concentrations of albumin, sodium and octanoate.These quantities are taken into account and any necessary furtheramounts of stock sodium chloride and sodium octanoate excipientsolutions and appropriate grade water added to achieve the bulkformulation specification. The final albumin concentration may be235-265 g·L⁻¹ (ie about 25%), with a sodium concentration of 130-160 mM.Any other feasible albumin concentration may be made, however, with, forexample, a minimum concentration of at least 4% (w/v), preferably 4-25%(w/v). Formulation is complete following addition of appropriateconventional pharmaceutically acceptable excipients, such as thosespecified in the US or European Pharmacopoeias for human albumin, anddiluting water.

A final concentration of 0.08 mmoles sodium octanoate per gram ofalbumin may be desirable. The product is sterile and non-pyrogenic.There may be about 1% (w/w) dimeric albumin but no larger polymers oraggregates are detectable as analysed by GP UPLC using a TSK SW3000XLcolumn.

EXAMPLE 4 Cation Exchange Followed Directly by Anion Exchange

In a variation of the process of Example 2, the order of the steps wasaltered and some changes were made in the process conditions. A furthertable of chromatographic solutions is therefore provided, as Table 3. Inaddition, all of the chromatographic columns except the gel permeationstep are radial flow.

TABLE 3 CHROMATOGRAPHY SOLUTIONS FOR EXAMPLE 4 Solution No. NameConstituent Concentration (g · L⁻¹⁾ pH (mS · cm⁻¹) CS20 SP-FFEquilibrant/Wash/ CH₃COOH 1.85 5.45-5.65 1.9-2.2 DE-FF Equilibrant NaOH(27% (w/w)) 4.00 CS23 SP-FF Eluent/ CH₃COOH 5.13 5.4-5.6 5.0-6.0 DE-FFPre-Equilibrant NaOH (27% (w/w)) 11.5 Octanoic Acid 0.721 CS24SP-FF/DE-FF Salt Clean NaCl 58.4 5-9 75-95 Tween 80 5.00 CS25 0.5M NaOH(UF membrane NaOH (27% (w/w)) 74.1 >12 80-120 clean) CS26 20 mM NaOHNaOH (27% (w/w)) 2.96 >12 3.5-5.5 CS27 DE-FF Wash K₂B₄O₇•4H₂O 4.809.0-9.4 2.5-3.5 CS29 DBA Equilibrant/Wash CH₃COONH₄ 19.3 8.7-9.1 18-22NaOH (27% (w/w)) 5.93 CS30 DBA Eluent NaCl 117 6.7-7.1 125-165 NaOH (27%(w/w)) 14.1 H₃PO₄ (85% (w/w)) 5.79 CS32 0.1M NaOH (UF membrane NaOH (27%(w/w)) 14.8 >12 16-24 storage) CS33 2M Sodium Octanoate NaOH (27% (w/w))281 7.8-8.4 — Octanoic Acid 288 CS34 Acetic Acid CH₃COOH 1045 — — CS350.5M Phosphoric Acid H₃PO₄ (85% (w/w)) 59.0  <1 — All weight tolerancesto ∀ 0.5%.

The initial cation exchanger step was essentially the same as in Example2, but with the following variations. The bed flow path length was11.0±1.0 cm. The chromatography was then carried out as follows.

An SP-FF (Pharmacia) column was equilibrated in four volumes of 10-100mM acetate, preferably 20-40 mM, for example 30 mM as in CS20, and thealbumin solution was loaded at a flow rate of 0.07 to 0.75 bed volumesper min, preferably 0.3-0.6, in this example 0.5 bed volumes per minute.The column was washed with eight volumes of 10-100 mM, preferably 30-70,for example 50 mM acetate (CS21) and, then ten volumes of CS20 and thealbumin eluted with, and collected in, an acetate/octanoate buffer (forexample 40-120, preferably 60-100, eg 85 mM acetate, and 2-50,preferably 2-20, eg 5 mM octanoate, as in CS23) using an A₂₅₄/cm of 0.6and 0.36 to mark the start and end of collection. The column is cleanedwith 0.25-3.0 M salt and 0.05-2% detergent (CS24) and then 0.1-1.0 Mcaustic (CS25) and stored in dilute (10-50 mM) caustic (CS26). In thisexample, the flow rate for the equilibration, loading and washing stepsis 0.5 bed volumes per minute. For elution of the albumin, a flow rateof 0.04-0.6 bed vol/min, preferably 0.15-0.35, in this example 0.25 bedvol/min is used. The anticipated recovery of rHA monomer is between 46and 66%.

The albumin was therefore eluted from the cation exchange column with asolution of octanoate, achieving a novel biospecific elution of rHA froma cation exchanger. The pH4 is close to the pI of the albumin so thatthe binding of the octanoate causes a significant overall chargedifference; for example, the pH is at least 4.5, preferably about pH5.5.

The eluate from the cation exchanger is then loaded directly (ie insteadof after affinity and gel permeation chromatography as in Example 2, butpreferably after dilution) onto the anion exchange resin at a pH of4.5-6.5, preferably about 5.5, and a conductivity preferably in therange 1.5 to 5.0 mS·cm⁻¹, for example 2.5±0.5 mS·cm⁻¹. This has beenfound to result in any dimeric albumin that was formed during the cationexchange chromatography being converted back to monomeric albumin underthe conditions of the anion exchange chromatography. A yield ofapproximately 110% for albumin monomer has been achieved over this step.

In more detail, an 11.0±1.0 cm bed flow path length column ofDEAE-Sepharose Fast Flow (Pharmacia) is pre-equilibrated with the cationexchange elution buffer (CS23) and then equilibrated with an acetatebuffer (for example CS20) before being loaded with 30.0∀10.0 g monomericalbumin per liter of matrix.

The column is then washed with a borate solution as in Example 2 (CS27),eluted as in Example 2 (CS06), and cleaned with salt/detergent (CS24),caustic (CS25) and stored in dilute caustic (CS26) all as for the cationexchange column. The flow rate for all the steps is 0.07 to 0.75 bedvol/min, preferably 0.3-0.6, in this example 0.5 bed volumes per minute.

The eluate from the anion exchange resin (eg DE-FF) still containsimpurities and is then applied directly to the affinity matrix (eg DeltaBlue Agarose as described in Example 2). The bed height was reduced from25 cm in Example 2 to 11.0±1.0 cm which allowed a higher flow ratewithin normal operating pressure. Therefore, a bed height of 11.0 cm waspreferred and does not adversely affect recovery of albumin or albuminpurity. The column was equilibrated in ammonium acetate (100-300 mM,preferably 200-275, for example 250 mM as in CS29) and the albumin wasapplied at 7.0-14.0 g/l, preferably 8.0-12.0 g/l, in this example10.0±1.0 g per liter of matrix. Equilibration, load and wash steps wereperformed at flow rates of 0.05-0.30 bed vol/min, preferably 0.15-0.27,in this example 0.25 bed vol/min. All other steps were performed at0.04-0.30, preferably 0.1-0.25, and in this example, 0.20 bed vol/min.The increased flow-rate, facilitated by the reduced bed height, improvedthe throughput by a factor of four which is advantageous to the largescale plant design and was close to the maximum operating capability ofthe DBA. Since this increased flow rate did not appear to adverselyaffect recovery of albumin or albumin purity, it is preferred to utilisesuch a higher flow rate.

The column was washed with 5 column volumes of the ammonium acetatebuffer (CS29), and the albumin was eluted with strong salt and phosphatesolution (1.0-3.0 M NaCl, for example 1.5-2.5 M or 2.0 M NaCl, and 5-100mM, eg 50 mM phosphate, as in CS30).

The pH of the eluant in this variant of the process was changed to pH7.0from pH9.2. The buffer was changed accordingly from 50 mM ammoniumacetate to 50 mM sodium phosphate which was preferred because of itsbuffering at pH7.0, and its relative cost. The lower pH eluant wasresponsible for an increase in DBA eluate albumin monomer recovery. A pHlower than 7.0 increased the fragment levels, and above pH7.0 thealbumin monomer recovery was reduced. The pH, which can be in the range5.5-9.0, is therefore preferably pH7.0. The column was cleaned andstored in caustic (CS25, CS26) as above.

The DBA eluate (optionally after ultrafiltration with a cellulosic typemembrane (nominal cut, off MW30,000) to give 80-110 g/l of albumin) wasthen applied to the gel permeation resin, for example S-200 (HR). TheS-200 running buffer was changed to 40 mM sodium phosphate pH7.0. Thesodium octanoate was omitted from this buffer for cost reasons, andinstead was added to the solution prior to diafiltration (added to aconcentration of 1-20 mM, preferably 5 mM). The phosphate conferred ahigher conductivity on the running buffer which improved the purity. Ahigh salt concentration can be used to increase conductivity but it isstill preferable to buffer the solution; The pH7.0 was preferable sincethis was the desired pH for formulation.

Hence, in this example, the sequence of purification steps is: cationexchange (eluting with a molecule specifically bound by albumin), anionexchange, affinity chromatography and gel permeation.

The diafiltration step prior to formulation may be assisted by startingwith albumin at pH7.0. The albumin was more concentrated at the finaleluate than with the process of Example 2, assisting the finalultrafiltration step prior to formulation (Example 3).

EXAMPLE 5 High Salt Wash on Cation Exchanger

In a further variation of the process, the process of Example 2 or 4 wasfollowed except as follows. Following loading of the albumin on to thecation exchange column (for example SP-Sepharose FF, Pharmacia), thecolumn was washed with CS21 (50 mM sodium acetate, pH 3.9-4.1, 0.6-0.8mS·cm⁻¹), then further washed with a high salt buffer containing 1-3MNaCl, preferably 2M NaCl, in sodium acetate buffer (for example 10-50 mMsodium acetate, preferably about 27 mM, pH 3.5-4.5, preferably pH4.0)before the final wash in CS20. This more stringent washing procedureresults in an eluate containing a lower level of non-albumin proteinsand may be especially useful if the albumin is rHA from a yeastfermentation. The albumin was eluted as described in Example 4. Thelowering of the pH prior to the high salt wash helps to retain thealbumin on the column during that wash, and the final wash alsomaximises albumin recovery. It is probable that neither step has a majoreffect on the purity of the albumin recovered.

EXAMPLE 6 Concentrated Borate Elution from Anion Exchanger

In this example, the process of Example 2 or 4 (with or without thevariation in Example 5) was varied as follows. The eluate from thecation exchange column was diluted to below 10 mS·cm⁻¹, preferably lessthan 5 mS·cm⁻¹, and then loaded on to an anion exchange matrix (forexample DEAE Sepharose FF, Pharmacia). The anion exchange matrix wasthen washed with dilute tetraborate buffer (for example 15-25 mMpotassium tetraborate or sodium tetraborate), which has the effect ofraising the pH to approximately 9.2, and then the albumin was elutedwith a more concentrated tetraborate buffer (for example 80-150 mMpotassium tetraborate, preferably 110 mM potassium tetraborate). InExamples 2 and 4, the albumin was eluted with 20 mM tetraborate, 100 mMNaCl; elution with 80-150 mM tetraborate (eg 33.6 g/l) results in aneluate with a lower content of carbohydrate-containing contaminants, forexample yeast glycoproteins, due to an increased affinity of thesespecies for the anion exchange matrix under these conditions. Potassiumtetraborate is used in preference to sodium tetraborate because of itshigher solubility at room temperature. The eluate from the anionexchange matrix was dealt with as in Example 2 or 4. For example, in theExample 4 process, it was then directly loaded onto an affinity matrix,eg Delta Blue Agarose (DBA), which was run as described in Example 4.

A gel permeation step is then carried out as in Example 2 or 4.

EXAMPLE 7 Immobilised Aminophenylboronate

The eluate from the DBA matrix may be applied to a gel permeationmedium, for example Sephacryl S-200 (HR) (Pharmacia), equilibrated in anammonium acetate buffer (for example 10-100 mM, preferably about 30 mM),containing sodium chloride (20-2000 mM, preferably about 100 mM) andoctanoate (1-20 mM, preferably about 5 mM octanoate at pH 9.0-9.5,preferably 9.2). This buffer effectively exchanges the albumin into asuitable solution for the final chromatographic step, set out in moredetail below.

The S-200 step is run as follows. The S-200 is run at a minimum bedheight of 90.0±3 cm (eg 3×30 cm in series). (a) The retentate fromintermediate ultrafiltration is loaded onto the column. Recycle andproduct fractions are collected. This step is repeated until all thematerial has been loaded onto the column. (b) The pooled recyclefractions are concentrated to 80-110 g rHA/L by ultrafiltration asabove. (c) The retentate from recycle ultrafiltration is loaded onto thesame column and a product fraction collected from each peak. This stepis repeated until all the material has been loaded onto the column. (d)The product fractions from the primary and secondary gel permeationchromatography steps ((a) and (c)) are pooled as the S-200 eluate.

The final step consists of an affinity step to remove glycoconjugates,such as glycoproteins and glycolipids, and poly, oligo- andmonosaccharides. This step uses immobilised aminophenylboronic acid(PBA) as the ligand. U.S. Pat. No. 4,562,251 (incorporated herein byreference) describes suitable methods for making diborotriazine agaroseor monoborotriazine agarose: (1) Triazine is O-linked to agarose firstand then linked with 3-aminophenylboronic acid (APBA) in a secondreaction. If the X on the triazine is replaced with chlorine then thedisubstituted resin is produced. (2) Triazine is reacted with APBA firstto produce either mono or diborotriazine. These are then O-linked viathe free chlorine on the triazine to the -ONa activated agarose toproduce either mono or disubstituted agarose. All of the examples anddescriptions in this patent use -ONa activated agarose which results inO-linkages.

An earlier patent U.S. Pat. No. 4,269,605 contemplates a variety ofmatrix activation methods, including epichlorohydrin activation ofagarose, preferred herein. Commercially available matrices includeAmicon's PBA30 and Sigma's acrylic beaded aminophenylboronate.

The albumin collected from the S-200 column was chromatographed throughthe PBA matrix, having been pre-equilibrated in S-200 running buffer(see above); under these conditions, the albumin does not bindappreciably to the matrix, whereas the carbohydrate-based contaminantsare retarded sufficiently to separate them from the albumin as it passesthrough the column. The chromatography is thus in the negative mode withrespect to the albumin. Further details were as follows:

The phenyl boronate matrix had a flow path length of 11.0±1.0 cm and wasequilibrated with a buffer containing ammonium ions (10-50 mM), acetate(10-50 mM) and 1.0-10.0 mM octanoate (eg CS36—see table below). Thecolumn was then loaded at 35±15 g of rHA/matrix. The PBA is run as anegative step and therefore the product collected is the flow throughduring loading and the subsequent wash with the equilibration buffer.All chromatographic steps can be performed at flow rates in the range0.005-0.3 bed vol/min. Preferably equilibration and cleaning of thecolumn are carried out at a higher flow rate, eg 0.19 bed vol/min, thanload and collection of the albumin solution, which is preferably carriedout at a flow rate of 0.01-0.05, preferably 0.025 bed vol/min. Thecolumn is then cleaned with a borate buffer (as in CS37), salt (CS38)and caustic (CS25) and then stored in the borate buffer (CS37).

The pH of the collected flow through and wash is adjusted to 7.0±0.1with phosphoric acid solution (CS35).

The buffers used are as follows:

TABLE 4 Chromatography solutions for Example 7 Solution ConcnConductivity No. Name Constituent (g/l) pH (mS · cm⁻¹) CS36 PBACH₃COONH₄ 2.31 9.0-9.4 12.0-15.0 equilibration/ NaOH (27% w/w) 2.55 washNaCl 5.84 Octanoic acid 0.721 CS37 Borate clean K₂B₄O₇•4H₂O 33.6 9.2-9.515.0-18.0 CS38 Salt clean CH₃COOH 1.62 3.9-4.1 125.0-165.0 NaOH (27%w/w) 1.19 NaCl 117.0

Because of the use of ammonium ions in the PBA buffer, it isadvantageous to use salt in the final ultrafiltration step, as explainedin Example 3 above.

In a particularly preferred process, the sequence of steps is asfollows:

-   (1) Yeast fermentation as in Example 1.-   (2) Centrate conditioning as: in Example 2.-   (3) Cation exchange (SP-FF) with high salt wash, as in Example 5,    and elution with albumin-specific compound, as in Example 4.-   (4) Dilution and anion exchange with concentrated tetraborate    elution as in Example 6.-   (5) Affinity chromatography (DBA) as in Example 4.-   (6) Intermediate ultrafiltration and then gel permeation (S-200),    with recycle ultrafiltration, as in Example 7.-   (7) Chromatography on immobilized borate as in Example 7.-   (8) Final ultrafiltration and formulation as in Example 3.

EXAMPLE 8 Earlier Use of Immobilised Phenylboronate

The step involving immobilised phenylboronate may be used earlier in theprocess, for instance in a process in which the steps are ordered:cation exchanger-anion exchanger-affinitymaterial-ultrafiltration/diafiltration-immobilised phenylboronate-gelpermeation.

The conditions for each step are as in Examples 4 to 7, except asfollows. The DBA eluate is concentrated to 80-110 g/l albumin and the pHis adjusted to 9.2 by diafiltering (5 volumes) against an ammoniumacetate of the kind used in Example 7. The concentrated DBA eluate isthen chromatographed on PBA and the flowthrough is collected and applieddirectly to the gel permeation (eg S200) column. As the gel permeationstep is now the last step, it may run in a buffer which is suited to theformulation step, for example 20-130 mM (preferably 50-100 mM) NaCl, atpH 7.0.

EXAMPLE 9 Characterisation of the Albumin Produced According to theInvention

This Example illustrates the analysis that is carried out to establishthe purity of albumin purified in accordance with the present invention.Unless stated otherwise, all of the assays are performed on albuminwhich has been formulated as described in Example 3 to yield the finalproduct.

Glycation of rHA

A microassay for glycated protein has shown that (rHA) purified inaccordance with the invention is not modified by non-enzymicglycosylation (glycation). The microassay measures the stable Amadoriproduct (AP) form of glycated protein, by oxidation of the C-1 hydroxylgroups of AP with periodate. The formaldehyde released by periodateoxidation is quantitated by conversion to a chromophore,diacetyldihydrolutidine (DDL), by reaction with acetylacetone inammonia. DDL is then detected colorimetrically at 405 nm.

Albumin batch Mole hexose/mole protein A 0.092 B 0.116 C 0.090 D 0.132 E0.060 G 0.04 H 0.01 I 0.07 J 0.07 K 0.05 L 0.740 M 0.70 N 0.96 O 0.78

Batches A-K were rHA purified according to Example 2. Batches L-O weresamples of commercially available human serum albumin from differingsources. Eight batches of rHA purified according to Example 7 had anegligible level of glycation (0.042±0.018 moles/mole) compared to HSA(0.387±0.012).

Low Molecular Weight Contaminant Assay

Rationale—The aim of this assay is to remove non-covalently bound lowmolecular weight contaminants (LMC) from rHA and HSA using acidicorganic solvents. An HPLC “fingerprint” chromatogram can then beproduced for comparison of samples.

Method—To 100 l of final product (20 mg; rHA or HSA) is addedsequentially 50 l formic acid (98% v/v), 100 l chloroform and 50 lethanol with vortexing after each addition. The samples are kept at roomtemperature for 5 mins with regular mixing. Protein is then precipitatedby the addition of 1 ml acetone (30 mins, 20° C.). The protein samplesare pelleted by centrifugation and the supernatants are decanted off anddried by rotary evaporation under vacuum. The dried samples areresuspended in 25% acetonitrile/0.1% trifluoroacetic acid. LMCs are thenseparated on an ABI PTH C18 reverse phase column (220×2.1 mm) using alinear 10%-90% acetonitrile gradient in 0.1% trifluoroacetic acid (flowrate=300 l/min). The samples were monitored at 214 nm using a ShimadzuUV monitor.

Results—A comparison was made between a commercially available batch ofhuman serum albumin and a batch of rHA purified according to theinvention. Two main significant A_(214nm) peaks are seen in the sampleof the invention (R_(t)=31.1 and 42.8 mins respectively—see FIG. 2 andTable 9). The peak at 2.15 mins is thought to be due to insoluble orpartially soluble material passing through the column, and the largepeak at 56.5 mins is also present in the trace of a water blank and thusis regarded as an artefact.

TABLE 5 Peak Results # Ret Time (min) Area (uV · sec) Height (uV) 10.800 3459686 219122 2 1.667 418606 33569 3 2.150 77883335 1963630 43.000 6293258 122295 5 20.433 297608 14424 6 22.900 205822 14601 727.567 150851 10835 8 31.117 2213883 170938 9 37.983 164710 15088 1039.267 347946 29879 11 41.750 107515 8402 12 42.783 2303024 192911 1343.217 139744 14141 14 43.457 254521 23979 15 50.467 152805 13226 1650.950 162364 12577 17 56.533 5753796 83674

The commercially available HSA, on the other hand, has many more peaks(see FIG. 3 and Table 6).

TABLE 6 Peak Results # Ret Time (min) Area (uV · sec) Height (uV) 10.350 244385 23957 2 0.633 607880 45310 3 0.783 3239730 243477 4 0.9831072033 158146 5 2.233 76773569 2038028 6 2.933 6634089 182363 7 3.7332812688 95459 8 12.483 818540 20185 9 12.650 218748 22750 10 14.1505423715 98336 11 16.333 423403 17460 12 16.633 688525 24538 13 17.5502301309 84781 14 18.033 1145045 47806 15 19.750 672721 21562 16 20.23387799 9760 17 20.700 272171 13003 18 21.100 862146 55792 19 21.967166471 8928 20 22.883 1381445 97660 21 23.583 1112632 89851 22 24.0004740347 419780 23 24.417 352486 26374 24 24.917 171279 14625 25 25.13399734 11473 26 25.267 133911 10515 27 25.667 223556 11854 28 25.967257295 17351 29 26.600 93906 7957 30 26.817 223113 18326 31 27.250303831 29461 32 27.533 124218 12710 33 27.783 5747091 561629 34 28.5501383761 119772 35 29.033 390986 33455 36 29.417 182131 12713 37 29.833181333 12584 38 30.183 478320 30155 39 30.583 1048945 58465 40 31.0673454425 214489 41 31.983 168275 8663 42 32.717 651406 43161 43 33.1501142221 102588 44 34.017 420756 23883 45 35.100 115704 10008 46 37.033166588 9468 47 38.267 145731 8078 48 38.983 781209 54029 49 41.800 869678868 50 48.883 95416 8522 51 50.267 174159 16737 52 50.483 176115 1557353 51.267 158727 13701 54 52.183 297278 25795 55 56.533 5846645 85710

The quality of the albumin of the invention in terms of non-covalentlybound LMCs is clearly superior to that of clinical HSA. Expressednumerically, the total peak area between 10 mins and 55 mins for thealbumin of the invention was about 6.4 V·sec whereas the total peak areabetween the same two times for commercially available material was about39.7 V·sec.

A similar analysis was carried out with detection at 280 nm, in whichcase the peak area for albumin purified according to the invention was0.56 V·sec, whereas that for HSA was 14.9 V·sec.

Analysis of fluorescent low molecular weight contaminants (excitation at280 nm, detection at 350 nm) again revealed a total peak area foralbumin purified by the process of the invention of less than 10% ofthat for HSA.

Capillary Zone Electrophoresis of rHA and HSA

Capillary electrophoresis (CE) is used as an alternative to standardSDS-PAGE in order to qualitatively compare purified rHA of the inventionand commercially available HSA. CE is a high resolving electrophoretictechnique and is capable of separating sub-populations of the sameprotein when only minor differences are to be found.

Method—Samples of HSA (Armour) and rHA purified according to theinvention were separated in 20 mM PO₄/B₄O₇ buffer, pH=7.4 at 20 KeV and30EC were electrophoresed on an ABI 270 CE. The rHA of the inventiongave a single peak on the electrophoretogram indicative of itshomogeneity. In contrast, other peaks were observed in the commerciallyavailable HSA samples. These peaks are believed to be indicative of thepresence of albumin molecules with, for example, blocked free thiolgroups or amino terminal degradation.

Analysis of C-Terminus

An important aspect of the quality control of recombinant proteins isthe confirmation and stability of the pre-determined primary structure.

Materials and Methods

Tryptic Digestion: HSA (from a commercial source—one sample stored at20° C. and one stored at 30° C. for 12 weeks), rHA purified according tothe invention (stored at 4° C. and 30° C. for 6 months) and a Des-LeurHA (a truncated form of rHA minus the C-terminal leucine) (1 mg each)were reduced with 5 mM dithiothreitol (Calbiochem) for 120 mm 37° C.,then alkylated with 10 mM iodoacetamide (Sigma) for 90 mins at 37° C. in6M guanidine HCl in 0.5M Tris HCl pH 8.0.

The samples were then diluted 1 in 3 with H₂O and digested with trypsinfor 48 hours at 37° C. (TPCK treated trypsin from Sigma, 3×10 l aliquotsof 1 mg/ml solution added over 48 hours).

Peptide Mapping: Tryptic digests were mapped on reverse phase (RP) HPLCon a Gilson HPLC system using a 25 cm Pharmacia SuperPac Pep-S column (5μM C₂/C₁₈). The eluents used were A, 0.1% (v/v) TFA (ABI) in water; B,0.09% (v/v) TFA in 70% (v/v) acetonitrile (Fisons Scientific)—lineargradient over 60 min, 0.5 ml/min. UV detection at 214 nm and 280 nm.

N-terminal Sequencing: Performed on an ABI 477A protein sequencer.

Fast Atom Bombardment-Mass Spectrometry: FAB-MS was performed on a VGAutospec by M-Scan Limited, Ascot, UK.

Peptide Synthesis: The full length C-terminal tryptic peptideLVAASQAALGL (mass 1012) (SEQ ID NO:1) was synthesised by ABI,Warrington, UK; and the truncated version LVAASQAALG (mass 899) (SEQ IDNO:2) was synthesised by the Department of Biochemistry, University ofNottingham, Nottingham, UK.

Results

The full length C-terminal tryptic peptide (mass 1012) was shown, usingthe synthetic marker peptide, to elute at 37.5 minutes on RP-HPLC. Thispeak was collected and identified by N-terminal Sequencing and FAB-MSfrom HSA and rHA.

Removal of the C-terminal leucine results in a truncated C-terminalpeptide (mass 899) which was shown to elute at 28.5 minutes, confirmedusing the synthetic marker peptide. This peak was isolated from thetryptic digest of Des-Leu rHA and identified by N-terminal Sequencingand FAB-MS. Two other peptides were shown to be present in this 28.5minute peak, AWAVAR (mass 673) and DLGEENFK (mass 950).

The 28.5 minute peak was collected off RP-HPLC from the tryptic digestsof HSA, HSA stored at 30° C. for 12 weeks, Des-Leu rHA, rHA of theinvention stored at 4° C. for 6 months and rHA of the invention storedat 30° C. for 6 months.

The peak from each digest was subsequently analysed by N-terminalSequencing and FAB-MS along with the synthetic marker peptides.

TABLE 7 Peptides present in 28.5 minute peak by N-terminal Sequencing.SAMPLE SEQUENCE Des-Leu rHA LVAASQAALG (SEQ ID NO:2) AWAVAR (SEQ IDNO:3) DLGEENFK (SEQ ID NO:4) HSA standard AWAVAR (SEQ ID NO:3)DLGEENFK + about (SEQ ID NO:4) 5% LVAASQAALG (SEQ ID NO:2) HSA 30° C. 12weeks AWAVAR (SEQ ID NO:3) DLGEENFK (SEQ ID NO:4) rHA 4° C. 6 monthsAWAVAR (SEQ ID NO:3) DLGEENFK (SEQ ID NO:4) rHA 30° C. 6 months AWAVAR(SEQ ID NO:3) DLGEENFK (SEQ ID NO:4)

By FAB-MS, the main signals ((M+H)⁺ molecular ions) present in the 28.5minute peak were as shown in Table 8.

TABLE 8 (M + H)⁺ Ions in 28.5 min Peak. Mixture of Synthetic Full Lengthand 1013- LVAASQAALGL Truncated C-terminal Peptides (SEQ ID NO:1) 900-LVAASQAALG (SEQ ID NO:2) Des-Leu rHA 673- AWAVAR (SEQ ID NO:3) 900-LVAASQAALG (SEQ ID NO:2) 951- DLGEENFK (SEQ ID NO:4) 1028- ? 1140- ? HSAStandard 673- AWAVAR (SEQ ID NO:3) 900- LVAASQAALG (SEQ ID NO:2) 951-DLGEENFK (SEQ ID NO:4) 1028- ? 1140- ? rHA 30° C. 6 months 673- AWAVAR(SEQ ID NO:3) 900- LVAASQAALG (SEQ ID NO:2) 1028- ? 1140- ? 951- Nosignal

The signals at 1028 and 1140 may be fragment ions; they were notpeptides that could be detected by sequence analysis.

CONCLUSION

The Des-Leu C-terminal tryptic peptide was detected in commercial HSA atapproximately 5-10% (not quantitative), but could not be detected in therHA of the invention, even after 6 months at 30° C. The Des-Leu peptidecould not be detected in the HSA 12 weeks at 30° C., and the peak forthe full length C-terminal peptide at 37.5 minutes (though not isolated)was very diminished compared to the other samples, indicating thatperhaps this has undergone further C-terminal degradation.

These results indicate that the rHA, purified in accordance with theinvention, has a stable and full length carboxy-terminus, whereas HSApreviously available from commercial sources appears to be heterogeneousby comparison.

Colorimetric Assay for Free Thiols in Purified Human Albumin

Introduction—Ellmann's Reagent, 5,5N-dithiobis-(2-nitrobenzoate) (DTNB),is a specific and sensitive means of detecting free thiol groups such asCys-SH. The reaction can be followed by monitoring absorbance at 412 nm,which value can be used to calculate free Cys-SH, to levels of less thanone residue per molecule of rHA. The following solutions reagents areutilised in the assay:

5,5N-Dithiobis (2-nitrobenzoic acid) DTNB, Sigma Product No D8130.

TRIS PRE-SET pH crystals pH8.0, Sigma Product No T4753.

EDTA, disodium, Sigma Product No ED2SS.

Sodium dihydrogen phosphate dihydrate, Analar grade.

Disodium hydrogen phosphate dihydrate, Analar grade.

Buffer 1: 0.1M (12.1 g) Tris-HCl; 0.01M (3.72 g) EDTA Na₂.2H₂O, pH8.0.PRE-SET pH crystals. Dissolve in 500 ml water and make up to 1 literexact volume. Stable for one month at room temperature.

Buffer 2: 0.05M Sodium phosphate pH7.0, Na₂HPO₄.2H₂O (5.45 g), 3.04 gNaH₂PO₄.2H₂O. Dissolve in 500 ml water, and make up to 1 liter exactvolume. Stable for 1 month at room temperature.

Reagent: 0.01M (39.4 mg) DTNB in phosphate buffer. Dissolve in 10 mlbuffer 2. Prepare fresh each day.

Sample: Dilute albumin to about 10.3 μM in buffer 1 (0.66 mg/ml).

Procedure

1) Set spectrophotometer cell holder thermostat to 25° C. 2) Place 1.25ml of sample in one cuvette and 1.25 ml of buffer 1 in another 10 mmreduced volume cuvette in the sample and reference positionsrespectively. 3) Zero instrument at 412 nm. Set absorbance to 0.1 AUFull Scale. 4) Add 50 l DTNB reagent to the reference cuvette, and mixbriefly using a cleaned plastic stirrer. 5) Add 50 l DTNB reagent to thesample cuvette, and mix as above. 6) Immediately start acquiring data(or start chart recorder, and follow reaction for up to 10 mins). 7)Repeat for each sample, to obtain values in triplicate. 8) Extrapolateback from the steady absorbance decay to zero time, and read off theabsorbance at 412 nm (A₄₁₂) (FIG. 1). 9) Calculate the sulphydrylcontent using the molar extinction coefficient A₄₁₂=13.9 cm²mM⁻¹.

Results

A number of commercial HSA samples were assayed for free thiol content,the results are summarised below:

Free Thiol HSA (mole SH/mole HSA) 1 0.29 2 0.22 3 0.35 4 0.05 5 0.08 60.46 7 0.36

These values are significantly lower than the value for albumin preparedaccording to the example above which is routinely assayed at 0.85-0.9mole SH/mole rHA.

The Determination of Metal Ion Contamination in Human Albumin byGraphite Furnace Spectroscopy

Standards and samples are atomised from a pyrocoated graphite tube. Theatomic absorption of the sample is detected using the followingconditions:—

Atomisation Metal Wavelength temperature ion nm EC Zn 213.9 1800 Cu327.4 2300 Fe 248.8 2400 Al 309.8 2500 Mn 279.8 2200

Aluminium was measured using a Perkin Elmer M2100 atomic absorptionspectrophotometer, a Perkin Elmer HGA-700 graphite furnace, a PerkinElmer AS-70 Autosampler with sample cups and an aluminium hollow cathodelamp. The reagents were AR grade magnesium nitrate, an aluminiumstandard solution (1000 ppm) and AR grade concentrated nitric acid. A1.00% w/v magnesium nitrate solution was made up with Milli-Q water. 15μl of aluminium standard solution was pipetted into the autosampler anddiluted to 1500 μl with 0.20% nitric acid solution. The procedure isrepeated with 15 μl of the solution obtained and then with 150 μL of thesolution subsequently obtained, to give a 10 ppb (μg/L) aluminiumsolution.

An albumin sample is diluted with 0.20% nitric acid solution to give analuminium concentration within the limits of the calibration graph. A1:2 dilution is usually sufficient.

Magnesium is measured similarly, using a Perkin Elmer AS-51 flameautosampler and a magnesium hollow cathode lamp. A Magnesium Standardsolution of 1000 ppm is diluted with Milli-Q water to give 0.1, 0.2, 0.5and 1.0 ppm standard solutions. The atomic absorption of the sample isdetected at 285.2 nm.

Copper, iron, manganese and zinc are measured in the same way asaluminium except that, for zinc, a 1.0 ppb (μg/l) standard solution isused instead of a 10 ppb solution. The concentration of metal ions wasdetermined in ng/L and then related to the concentration of albumin (ngmetal ion/g albumin). These data are presented in Table 9.

TABLE 9 Contamination Profiles of Albumin produced according to theinvention Concentration in ng/g albumin Chemical Batch A Batch B Batch CAluminium — 85 — Copper 3720 9080 1780 Iron 460 810 440 Magnesium 1200850 800 Zinc 4510 1490 1790 Manganese 20 191 16 Chemical Batch D Batch EBatch F Batch G Aluminium — — — — Copper 660 2690 440 530 Iron 930 3802720 1880 Magnesium — — — — Zinc 1580 680 3520 2130 Manganese 42 14 5827 Chemical Batch H Batch I Batch J Batch K Aluminium 9 22 86 96 Copper520 590 9920 8820 Iron 1010 670 1030 100 Magnesium 600 <400 2000 2000Zinc 1740 1040 4280 3520 Manganese 35 20 46 60 All results are expressedas total metal ion concentration.

Table 10 shows the corresponding levels of metal ions in commercial HSA.

TABLE 10 Concentrations in ng metal/g of albumin Source A Source BSource C Source D Chemical (UK) (UK) (Japan) (Japan) Aluminium 790 970915 420 Copper 2020 4510 23840 580 Iron 41220 15200 23550 15240Magnesium 4500 500 15000 54000 Zinc 7230 1650 930 4580 Manganese 940 190135 240 Source E Source F Source G Chemical (UK) (USA) (France)Aluminium 350 3190 155 Copper 4830 1180 7910 Iron 7910 25920 1850Magnesium 1500 500 500 Zinc 1520 3940 2130 Manganese 160 65 80

It can be seen that the average level of aluminium in the product of theinvention was about 60 ng/g whereas the commercial sources had 155-3190ng/g. Likewise, the product of the invention had an average of about 948ng/g iron (compare 1850-41,200 ng/g in prior art material), an averageof 2,990 ng/g of copper (compare 580-23,840 ng/g in prior art material),an average of 1,120 ng/g of magnesium (compare 500-54,000 ng/g in priorart material); an average of 2,390 ng/g of zinc (compare 930-7,230 ng/gin prior art material, and an average of 48 ng/g manganese (compare 65to 940 ng/g in prior art material).

Analysis of Medium and Long Chain Fatty Acids

The fatty acids profiles of albumin according to the invention andcommercially available HSA were analysed by acidic solvent extractionand gas chromatography of the free fatty acids using a C17:0 internalstandard.

Equipment: Gas chromatograph (eg Shimadzu GC 9A) with flame ionisationdetector; Autoinjector (eg Shimadzu AOC 14); Integrator/Printer (egShimadzu CR4A); HP-FFA 30×0.53 mm, 1.0 μm phase column (Hewlett PackardLtd); Megabore Installation kit (J & W Scientific 220-1150 for GC 9A)with direct injection liner.

Reagents: Water (Milli-Q); Dichloromethane Super Purity Solvent (RomilChemicals, Loughborough, Leics.); Sodium Acetate Trihydrate Analar (BDHLtd, Poole); Acetic Acid Glacial Analar (BDH Ltd, Poole); Human SerumAlbumin Solution (Zenalb™20, Bio Products Laboratory, Elstree, Herts);Sodium Sulphate Anhydrous (Analytical Reagent); standard fatty acidsfrom Sigma.

Solutions:

0.5M Sodium Acetate Buffer pH 4.5: Sodium Acetate 6.13 g and Acetic Acid3.30 g per 100 ml.

Free Fatty Acid standard mixtures. Weigh 5 mg of each fatty acid intoseparate glass vials. Dissolve each fatty acid in 1 ml Dichloromethaneand transfer to three 12 ml Pyrex culture tubes respectively for shortchain (C6-C14), medium chain (C16-C18) and long chain (C20-C22:1) fattyacids. Dry down mixture under a stream of nitrogen and dissolve in 1 mlDichloromethane. Transfer 50 l aliquots of mixture into labelled glassvials, dry under nitrogen, cap and store at −20° C.

Internal Standard Solution 1 mg/ml Heptadecanoic Acid (25.0 mgHeptadecanoic Acid/25 ml Dichloromethane).

Procedure

-   1. Add 50 μl Internal Standard Solution to 6 labelled 40 ml Pyrex    tubes.-   2. For 5% rHA add 5 ml sample. For 25% rHA use 1 ml sample and 4 ml    water. Include a blank (5 ml water) and serum albumin sample (1.25    ml Zenalb™20 and 3.75 ml water). Prepare all samples in duplicate.-   3. Add 2.5 ml Sodium Acetate Buffer, then 10 ml Dichloromethane to    all tubes.-   4. Place the capped tubes on a mechanical roller for 2 hours at room    temperature.-   5. Centrifuge all tubes for 5 mm at 3,000 rpm in a Sorvall RT6000B    centrifuge at 20° C.-   6. Remove the upper aqueous phase, then working from the bottom of    the tube carefully transfer the lower Dichloromethane phase into a    labelled 12 ml Pyrex tube. Protein globules may hinder the removal    of all the Dichloromethane phase. If this occurs add a spatula full    of Anhydrous Sodium Sulphate, cap and shake.-   7. Dry Dichloromethane phase under a stream of nitrogen and store    under nitrogen at 20° C. until analysis.-   8. Install the capillary column and set the gas chromatograph to the    following conditions according to the manufacturer's instructions:—    Detector: Flame ionisation; Carrier Gas: Nitrogen at 30 ml min⁻¹;    Injection Volume: 0.5 l; Column initial temperature: 70° C.; Hold:    1.5 mm; Gradient 1: 20° C. min⁻¹ to 150° C.; Gradient 2: 4° C. min⁻¹    to 240° C.; Hold: 7 min; Detector Temperature: 280° C.; Setting    Specific to Shimadzu GC9A are: Detector Range: 10°; Hydrogen    Pressure: 0.5 kg/cm²; Air Pressure: 0.5 kg/cm²; Stop Time: 50 mm.-   9. Set up the integrator to collect data from the gas chromatograph    according to the manufacturer's instructions.-   10. Raise oven temperature to 245° C. and leave until a steady    baseline is achieved.-   11. Lower oven temperature to 70° C. and allow to equilibrate.-   12. Thaw an aliquot of the Long, Medium and Short Chain Fatty Acid    standards. Dissolve the Long Chain Fatty Acids in 1 ml    Dichloromethane. Transfer the solution to the Medium Chain Fatty    Acids and dissolve. Repeat for the Short Fatty Acids.-   13. Inject the standard mixture to determine fatty acid retention    times. The chromatogram produced should have very little peak    tailing and have a smooth slowly rising baseline with the correct    number of well resolved peaks. Caproic Acid (C6:0) should elute with    a retention time of approx. 6 min and Erucic Acid (C22:1) with a    retention time of approx. 33 min. Identify all peaks by comparison    with example standard chromatogram.-   14. Inject samples and collect data.    Calculations-   1. Identify the internal standard peak from the blank samples. This    will be the major peak with a retention time of approximately 23.5    min.-   2. Calculate the Peak Area Ratios for all integrated peaks in all    samples using the following formula.

${{Peak}\mspace{14mu}{Area}\mspace{14mu}{Ratio}} = \frac{{Peak}\mspace{14mu}{Area}}{{Internal}\mspace{14mu}{Standard}\mspace{14mu}{Peak}\mspace{14mu}{Area}}$

-   3. Identify fatty acid peaks in rHA and HSA samples based on    retention time by comparison with standards.-   4. Convert all Peak Area Ratios to approximate concentrations (μg/g    albumin) for both rHA and HSA samples using the following factor:—    Concentration(μg/g)=Peak Area Ratio×200-   5. For peaks identified as fatty acids convert Concentration from    μg/g albumin to mole/mole albumin using the fatty acid's molecular    weight and the following formula:

${{Concentration}\mspace{14mu}\left( {{mole}/{mole}} \right)} = \frac{{Concentration}\mspace{14mu}{\left( {µ\; g\text{/}g} \right) \times 0.0665}}{{Fatty}\mspace{14mu}{Acid}\mspace{14mu}{Molecular}\mspace{14mu}{Weight}}$

Example results are presented for a batch of albumin prepared accordingto Example 2 (FIG. 4) and commercial HSA (FIG. 5). No abnormal fattyacids have been detected in the former by this method although theprofiles for the two proteins showed significant differences. Asexpected, both showed large amounts of the added stabiliser, octanoate(C8:0). Apart from this, commercial HSA was characterised bypredominantly C16:0, C16:1, C18:0, C18:1 and C18:2 whilst the albumin ofthe invention contained mainly C10:0, C12:0, C16:1 and occasionallyC14:0. Further experiments showed that the levels of C10:0 and C12:0 inrHA final product correlated with the levels of these contaminants inthe octanoate used for the latter stages of the purification process.

Data for the rHA produced according to Example 7 are as follows:

TABLE 11 Comparison of the fatty acid composition of rHA purifiedaccording to the process of the invention and commercial HSA. Fatty acidcontent (mol/mol protein) Fatty acid rHA HSA C10:0 0.100 0.005 C12:00.020 0.011 C14:0 0.005 0.017 C16:0 0.013 0.152 C16:1 0.064 0.023 C18:00.002 0.024 C18:1 0.012 0.145 C18:2 ND 0.089 C18:3 ND 0.006 C20:0 ND0.001 C20:1 ND 0.001 C20:2 ND ND C20:4 ND 0.006 TOTAL 0.216 0.480 ND =Not detected.

Preferably, the total level of C18 fatty acids does not exceed 1.0%(mole/mole) of the level of octanoate, and preferably does not exceed0.5% of that level. Moreover, in the albumin of the invention, the levelof C18:2, C18:3 and C20 fatty acids is generally undetectable. Incommercial HSA, there may typically be about 0.4 moles C10 to C20 fattyacids per mole of albumin. In the product of the invention, there istypically no detectable C20 fatty acids and only about 0.01 to 0.02moles C18 fatty acids per mole of albumin.

Analysis of Colour—The absorbance of a 5% (w/v) solution of the finalproduct in a 1 cm cuvette was measured at 350 nm, 403 nm and 500 nm andcalculated in terms of absorbances per gram of albumin/liter per cmpathlength (ie A L·g⁻¹·cm⁻¹). The albumin of the invention has thefollowing values:

Wavelength Mean absorbance (n = 10 batches) (nm) (L · g⁻¹ · cm⁻¹) 3504.74 × 10⁻³ 403 2.12 × 10⁻³ 500 0.58 × 10⁻³

Generally, the albumin of the invention does not exceed respectiveabsorbances of 6.0×10⁻³, 2.5×10⁻³ and 0.75×10⁻³ at the said threewavelengths.

Assays of a number of commercially available HSA preparations revealedhigher absorbances at these wavelengths (see Table 12).

TABLE 12 Absorbance (L · g⁻¹ · cm⁻¹) of prior art HSA preparationsSAMPLE A₃₅₀ A₄₀₃ A₅₀₀ 1 9.95 4.10 0.8 2 9.25 5.36 1.1 3 7.40 3.26 0.6 47.20 3.60 0.6 5 8.68 4.08 0.8 6 11.45 6.26 1.2 7 7.20 3.70 0.8 8 6.824.78 1.8

SDS reducing polyacrylamide gel electrophoresis—This assay is performedto show that rHA consists of a single polypeptide chain which whentreated with a reducing agent (β-mercaptoethanol) migrates as a singleband (monomer) on SDS reducing polyacrylamide electrophoresis (PAGE).

Samples of albumin were boiled in SDS reducing buffer (20 mM Tris-HCl pH8.0 containing 2 mM EDTA, 5% (w/v) SDS and 10% (v/v) β-mercaptoethanolwith the albumin at 1 mg/ml, and then separated on SDS homogeneous(12.5%) Phastgels (Pharmacia), using a loading of 1 μl of the solution.Protein bands were detected by Coomassie Blue R250 staining, scanned ona Shimadzu CS9000 densitometer. Separation of albumin showed a singleband of Coomassie staining which is indicative that the proportion ofalbumin present as a monomer is at least 99.9%.

Gel Permeation High Pressure Liquid Chromatography

25 μl of a 10 mg/ml solution of the albumin in the eluate from the anionexchange matrix in the main embodiment of the process of the invention(ie where the anion exchange step is the final step beforeultrafiltration and formulation) is injected onto a TSK3000SWXL columnon a Shimadzu LC6A HPLC. The product was found to be at least 99.9%monomeric.

25 μl of a second 10 mg/ml solution of albumin purified in accordancewith the invention which had been formulated to 25% w/v was assayed inthe same manner and found to contain less than 0.1% polymeric albumin.This result indicates that the formulation as described herein has noeffect on the polymer/aggregate content of the purified albumin.

Two Dimensional Gel Electrophoresis

2 μg rHA of albumin prepared by the process of the invention was subjectto two-dimensional electrophoresis using a Millipore Investigatorsystem. The separation in the first dimension was a pH 3-10 isoelectricfocusing gel and was followed by a 10% polyacrylamide/SDS gel in thesecond dimension. On staining of the gel with Coomassie Blue, only onespot was visible, indicating the presence of only one protein species.

Electrospray Mass Spectrometry

Electrospray mass spectrometry (ESMS) was performed using a VG Quattroelectrospray mass spectrometer, calibrated with horse heart myoglobin(16951 Da, obtained from Sigma) over m/z range 950-1750 Da/e. Samples ofcommercially available HSA and samples of rHA purified according to theinvention were desalted prior to analysis by reverse phase HPLC using anacetonitrile gradient containing trifluoroacetic acid. FIGS. 6 a and bshow the spectra for albumin of the invention and prior art HSA,respectively. The latter shows peaks representing blocked free thio andN-terminal degradation.

The albumin of the invention can be seen to be substantially homogeneousin this assay, in other words it shows a single defined peak, occurringat a mass of about 66441 Da.

Long Term Stability

Over two years, no degradation of the albumin is detectable byelectrophoretic methods, which shows that no protease activity ispresent.

1. A process for producing albumin from a yeast culture medium obtainedby culturing yeast transformed with an albumin-encoding nucleotidesequence in a fermentation medium and filling a container with thealbumin, whereby said yeast expresses and secretes the albumin, theprocess comprising (a) separating the yeast from the culture medium tothereby yield an albumin solution; (b) subjecting the albumin solutionto (1) cation exchange chromatography, wherein albumin is bound to acation exchange material and then the bound albumin is eluted from thecation exchange material; (2) affinity chromatography, wherein albuminis bound to an affinity chromatography material comprising analbumin-binding compound and then the bound albumin is eluted from theaffinity chromatography material; and (3) anion exchange chromatography,wherein albumin is bound to an anion exchange material and the albuminis eluted from the anion exchanger material; (c) concentrating andformulating the albumin with sodium octanoate and sodium chloride; and(d) filling a container with the albumin obtained from step (c).
 2. Aprocess according to claim 1 wherein the albumin is obtained from ayeast culture medium that is fermented at 30° C. at pH 5.7±0.2.
 3. Aprocess according to claim 1 wherein said filling of a container withalbumin involves filling a vial.
 4. A process according to claim 1wherein, prior to the cation exchange, the albumin is conditioned byadding octanoate thereto to a final concentration of from about 1-10 mMand adjusting the pH to about 4.0-5.0.
 5. A process according to claim 1wherein the yeast is S. cerevisiae.
 6. A process according to claim 5wherein the albumin is obtained from a yeast culture medium that isfermented at 30° C. at pH 5.7±0.2.
 7. A process according to claim 1wherein said separating is performed by centrifugation.
 8. A processaccording to claim 7 wherein the centrifugation is continuouscentrifugation.